Insulation structure for an appliance having a uniformly mixed multi-component insulation material, and a method for even distribution of material combinations therein

ABSTRACT

An insulation structure for an appliance includes a cabinet having an outer wrapper and an inner liner, with an insulating cavity defined therebetween. Insulating powder material is disposed substantially throughout the insulating cavity. An insulating gas is disposed within the insulating cavity, wherein the insulating powder material is combined with the insulating gas and cooperatively defines a suspended state and a precipitated state. The suspended state is defined by the insulating gas in motion and the insulating powder being in an aeolian suspension within the insulating gas while in motion. The precipitated state is defined by the insulating gas being in a deposition state and the insulating powder being precipitated from the insulating gas and deposited within the insulating cavity.

BACKGROUND

The device is in the field of insulating materials for various householdappliances, specifically, a multi-component insulation material that isuniformly distributed throughout an insulating cavity for the appliance.

SUMMARY

In at least one aspect, an insulation structure for an applianceincludes a cabinet having an outer wrapper and an inner liner, with aninsulating cavity defined therebetween. A plurality of hollow insulatingspheres is disposed within the insulating cavity, wherein a secondaryinsulating volume is defined between the plurality of hollow insulatingspheres and an interior surface of the cabinet. The interior surface ofthe cabinet defines the insulating cavity. An insulating fill materialdisposed within the secondary insulating volume, wherein the insulatingfill material and the plurality of hollow insulating spheres define asubstantially uniform insulating material.

In at least another aspect, a method of forming an insulating structureincludes forming an insulating member, wherein the insulating memberincludes an interior surface that defines an interior insulating cavity.The method also includes forming a plurality of hollow insulatingspheres and forming a fill material, wherein the fill material isdefined by a nano-sized particulate or powder material. The method alsoincludes disposing the hollow insulating spheres and thenano/micro-sized particulate material within the interior insulatingcavity. The method also includes dispersing the nano/micro-sizedparticulate material throughout a secondary insulating volume definedwithin the interior insulating cavity and within the interstitial spacedefined between the plurality of hollow insulating spheres, wherein thenano/micro-sized particulate material and the hollow insulating spheresat least partially define a substantially uniform insulating material.

In at least another aspect, a method of forming an insulating materialto be used in an insulating structure of an appliance includes forming aplurality of hollow insulating spheres, wherein a secondary insulatingvolume is defined within an interstitial space defined between theplurality of hollow insulating spheres. The method also includes forminga fill material, wherein the fill material is defined by anano/micro-sized particulate material. The method also includesdispersing the nano/micro-sized particulate material throughout asecondary insulating volume, wherein the nano/micro-sized particulatematerial and the hollow insulating spheres at least partially define asubstantially uniform insulating material.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of an appliance incorporating anaspect of the multi-component insulation material;

FIG. 2 is a schematic section view of a device for depositing and evenlydistributing an aspect of the multi-component insulation material evenlythroughout the insulating cavity;

FIG. 3 is a schematic section view of a device for depositing and evenlydistributing an aspect of the multi-component insulation material evenlythroughout the insulating cavity;

FIG. 4 is an enlarged cross-sectional view of an aspect of themulti-component insulation material;

FIG. 5 is an enlarged cross-sectional view of an aspect of themulti-component insulation material;

FIG. 6 is a schematic section view of a device for depositing and evenlydistributing an aspect of the multi-component insulation material evenlythroughout the insulating cavity;

FIG. 7 is a schematic section view of a device for depositing and evenlydistributing an aspect of the multi-component insulation material evenlythroughout the insulating cavity;

FIG. 8 is an enlarged perspective view illustrating an aspect of amulti-component insulating material incorporating a particulate materialand an insulating gas;

FIG. 9 is a perspective view of a multi-component insulating materialincorporating multiple forms of particulate material and an insulatinggas;

FIG. 10 is a schematic cross-sectional view of an insulating structurefor an appliance;

FIG. 11 is a schematic cross-sectional view of an insulating structurefor an appliance being injected with at least one component of amulti-component insulation material;

FIG. 12 is a schematic cross-sectional view of the insulating structureof FIG. 11 showing the injection of a second component of themulti-component insulation material;

FIG. 13 is a schematic cross-sectional view of the insulating structureof FIG. 12 illustrating the injection of a third component of themulti-component insulation material;

FIG. 14 is an enlarged cross-sectional view of an aspect of themulti-component insulation material installed within an insulatingcavity for an appliance;

FIG. 15 is a schematic flow diagram illustrating a method for forming aninsulating structure;

FIG. 16 is a schematic flow diagram illustrating a method for forminginsulating material to be used in an insulating structure of anappliance;

FIG. 17 is a schematic flow diagram illustrating a method for forming aninsulated structure; and

FIG. 18 is a schematic flow diagram illustrating a method for forming aninsulating member within an insulating structure.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As illustrated in FIGS. 1-9, reference numeral 10 generally refers to aninsulating structure for an appliance 12, where the insulating structure10 includes a multi-component insulating material 14 having thermaland/or acoustical insulating properties. According to the variousembodiments, the individual components of the multi-component insulatingmaterial 14 are disposed within the insulating cavity 16 to be placed ina substantially uniform configuration throughout the insulating cavity16 of the insulating structure 10. According to the various embodiments,an insulating structure 10 for an appliance 12 includes a cabinet 18having an outer wrapper 20 and an inner liner 22, where the insulatingcavity 16 is defined therebetween. An insulating powder material 24 canbe disposed throughout the insulating cavity 16. It is contemplated thatan insulating gas carrier 26 can also be disposed within the insulatingcavity 16, where the insulating powder material 24 is combined with theinsulating gas carrier 26 to cooperatively define a suspended state 28and a precipitated state 30.

According to the various embodiments, the suspended state 28 is definedby the insulating gas carrier 26 in motion or in an active state 32 andthe insulating powder material 24 being an aeolian suspension 34 withinthe insulating gas carrier 26 while in motion in the active state 32.Typically, the active state 32 of the insulating gas carrier 26 isdefined within the insulating cavity 16 before the insulating cavity 16is sealed and enclosed.

Referring again to FIGS. 1-9, the precipitated state 30 of theinsulating powder material 24 and the insulating gas carrier 26 isdefined by the insulating gas carrier 26 being substantially in adeposition state 36 and the insulating powder material 24 beingprecipitated from the insulating gas carrier 26 and deposited within theinsulating cavity 16. It is contemplated that in addition to theinsulating powder material 24, a plurality of hollow insulating spheres38 can also be disposed in the insulating cavity 16, where variouscombinations of the insulating powder material 24, insulating gascarrier 26, and plurality of hollow insulating spheres 38 cooperativelydefine the multi-component insulating material 14 disposed within theinsulating cavity 16. It is further contemplated that these componentscan be disposed in a substantially uniform configuration throughout theentire insulating cavity 16 such that the instance of pockets, sectionsor other portions of only one component of the multi-componentinsulating material 14 is substantially minimized. Various methods forachieving the uniform distribution of the individual components of themulti-component insulating material 14 will be discussed in greaterdetail below.

According to the various embodiments, as exemplified in FIGS. 1-9, it iscontemplated that the insulating gas carrier 26 can be at least one ofargon, neon, carbon dioxide, xenon, krypton, combinations thereof, andother similar insulating gasses that typically have insulatingproperties greater than that of air. In addition, the hollow insulatingspheres 38 can be made of various organic and/or inorganic materialsthat include, but are not limited to, glass, ceramic, polymers,combinations thereof, and other similar organic and/or inorganicmaterials. It is further contemplated that the insulating powdermaterial 24 can be defined by various particulate material that caninclude, but is not limited to, fumed silica, precipitated silica,nano-sized and/or micro-sized aerogel powder, rice husk ash powder,perlite, cenospheres, diatomaceous earth, combinations thereof, andother similar insulating particulate material. The insulating powdermaterial 24 can be disposed within the insulating cavity 16 of thecabinet 18 in various configurations, where such configurations includean uncompressed powder state, or can be disposed where the insulatingpowder material 24 includes compressed portions that define a densifiedinsulating granular material. In such an embodiment, the insulatinggranular material can be surrounded by uncompressed portions of theinsulating powder material 24, the insulating gas carrier 26, hollowinsulating spheres 38, combinations thereof, and other similarinsulating materials. In the various configurations of the insulatingpowder material 24, the insulating powder material 24 defines porousareas 40 defined between the individual particles and/or granules of theinsulating powder material 24. It is contemplated that the insulatinggas carrier 26 can occupy the various porous areas 40 that are definedbetween the particles of the insulating powder material 24. It isfurther contemplated that individual particles of the insulating powdermaterial 24 can occupy the porous areas 40 between the hollow insulatingspheres 38 and/or granular portions of the insulating powder material24.

Referring again to FIGS. 2-9, it is contemplated that in order todeposit the various components of the multi-component insulatingmaterial 14 into the insulating cavity 16 of the cabinet 18, the cabinet18 can include one or more inlet ports through which the insulatingpowder material 24 and the insulating gas carrier 26 are injected intothe insulating cavity 16. During injection of the insulating powdermaterial 24 and the insulating gas carrier 26 that combine to form theaeolian suspension 34, one or more vacuum ports 44 of the cabinet 18 canbe used to express portions of gas 46, such as air, that may be presentwithin the insulating cavity 16. It is also contemplated that during theexpression of gas 46 through the vacuum port 44, portions of theinsulating gas carrier 26 can also be expressed. In this manner, as theaeolian suspension 34 of the insulating gas carrier 26 and insulatingpowder material 24 flow through the insulating cavity 16, the expressionof the insulating gas carrier 26 provides for substantially continuousflow of the aeolian suspension 34 through the entire insulating cavity16. In this manner, precipitation of the insulating powder material 24from the aeolian suspension 34 can be substantially consistentthroughout the insulating cavity 16. In this manner, the aeoliansuspension 34 can be used to distribute, in a substantially uniformpattern, at least the insulating gas carrier 26 and the insulatingpowder material 24. As the insulating gas carrier 26 is expressed, it iscontemplated that at least a portion of the expressed insulating gascarrier 26 can be recycled for later use in combining with theinsulating powder material 24 to form the aeolian suspension 34 forfurther deposition of the insulating powder material 24.

According to the various embodiments, the aeolian suspension 34 of theinsulating gas carrier 26 and the insulating powder material 24 canoccur as the insulating gas carrier 26 moves past, through, or proximateto the insulating powder material 24. The fine particle size of theinsulating powder material 24 makes the individual particles of theinsulating powder material 24 light enough that they can be carriedthrough movement of the insulating gas carrier 26, and suspended withinthe insulating gas carrier 26 to form the aeolian suspension 34. Due tothe movement of the aeolian suspension 34 within the insulating cavity16 of the cabinet 18, deposition of the insulating powder material 24from the aeolian suspension 34 occurs. This deposition can be caused byvarious eddies 60, areas of turbulence within the insulating cavity 16,and other aerodynamic features that slow, re-direct or otherwise modifythe flow of the aeolian suspension 34 through the insulating cavity 16.These eddies 60 can be produced by structures disposed within theinsulating cavity 16 such as hollow insulating spheres 38, turbulenceproducing structures 62 attached to the inner liner 22 and/or the outerwrapper 20, combinations thereof and other similar turbulence producingfeatures. Such modification of the flow of the aeolian suspension 34results in the deposition of the insulating powder material 24 from theaeolian suspension 34. As a result of the injection of the aeoliansuspension 34, the insulating cavity 16 is eventually filled with theprecipitated insulating powder material 24 to fill all of, orsubstantially all of, the insulating cavity 16 of the cabinet 18. Aswill be described more fully below, the aeolian suspension 34 can beinjected into a substantially hollow insulating cavity 16, or can beinjected into an insulating cavity 16 that includes one or morecomponents of the multi-component insulating material 14, where suchcomponents can include, but are not limited to, hollow insulatingspheres 38, granular portions of the insulating powder material 24, foaminsulation, organic fiber, inorganic fiber, combinations thereof orother insulating material that includes various porous areas 40 betweenindividual particles.

Referring again to FIGS. 5-14, the insulation structure for theappliance 12 can include a cabinet 18 having the outer wrapper 20 andthe inner liner 22, with the insulating cavity 16 defined therebetween.According to various embodiments, a plurality of hollow insulatingspheres 38 can be disposed within the insulating cavity 16. In such anembodiment, a secondary insulating volume 70 is defined between theplurality of hollow insulating spheres 38 and the interior surface 72 ofthe cabinet 18. The interior surface 72 of the cabinet 18 serves todefine the insulating cavity 16. An insulating fill material 74 isdisposed within the secondary insulating volume 70, where the insulatingfill material 74 and the plurality of hollow insulating spheres 38define the uniformly distributed multi-component insulating material 14.The insulating fill material 74 can be made of various particulate andgaseous matter that can include, but is not limited to, nano-sizedand/or micro-sized porous material in the form of any one or more offumed silica, precipitated silica, aerogel powder, perlite, rice huskash powder, diatomaceous earth, cenospheres, combinations thereof, andother nano/micro-sized particulate material 76, such as the insulatingpowder material 24. The nano-sized porous material can also include atleast one opacifier, including, but not limited to carbon black, siliconcarbide, combinations thereof and other opacifiers. The insulating fillmaterial 74 can also include an insulating gas carrier 26, where theinsulating gas carrier 26 includes, but is not limited to, argon, neon,carbon dioxide, xenon, krypton, combinations thereof, and other similarinsulating gasses.

According to the various embodiments, the hollow insulating spheres 38can include an interior region 78 that is filled with one or moreinsulating gasses, sulfur, other gaseous material, or can include a lowpressure region that defines a partial vacuum within the interior region78 of the hollow insulating sphere 38.

According to the various embodiments, it is contemplated that theinsulating cavity 16 that contains the uniform distribution of themulti-component insulating material 14 is hermetically sealed to containthe multi-component insulating material 14 within the insulating cavity16. In such an embodiment, it is contemplated that the insulating cavity16 further defines an at least partial vacuum to create a vacuuminsulated structure 80. It is further contemplated that the vacuuminsulated structure 80 can be a vacuum insulated cabinet 18 for anappliance 12, a vacuum insulated panel that can be disposed within acabinet 18 of an appliance 12, various vacuum insulated structures 80for appliances 12 and other fixtures, as will be described more fullybelow.

Referring again to FIGS. 5-14, where the hollow insulating spheres 38are one of the components of the multi-component insulating material 14,it is contemplated that each hollow insulating sphere 38 can include anoutside diameter in a range of from approximately 50 nanometers toapproximately 300 microns. It is also contemplated that the hollowinsulating spheres 38 can be defined by various nano-spheres that caninclude a diameter in a range of from approximately 50 nanometers toapproximately 1000 nanometers. It is further contemplated that othersized microspheres and nano-spheres can be included individually or incombination with other sized microspheres and nano-spheres to provide abetter fill rate within the insulating cavity 16 of the hollowinsulating spheres 38 and also the other components of themulti-component insulating material 14. In the various embodiments, itis contemplated that the secondary insulating volume 70 defined betweenthe adjacent hollow insulating spheres 38 in a closed packed situationwithin the insulating cavity 16 can include a thickness in a range offrom approximately 40 nanometers to approximately 200 microns.Sub-nanometer thicknesses of portions of the secondary insulating volume70 are also contemplated. It is also contemplated that this secondaryinsulating volume 70 is large enough to receive other components of themulti-component insulating material 14, such as the insulating powdermaterial 24 in the powder or granular form, as well as the insulatinggas carrier 26. According to various embodiments, it is furthercontemplated that the secondary insulating volume 70 includes areas thatare large enough to receive and allow the aeolian suspension 34 to passbetween the individual hollow insulating spheres 38 to allow forprecipitation of the insulating powder material 24 from the aeoliansuspension 34 into the secondary insulating volume 70.

According to the various embodiments, in addition to the use of theaeolian suspension 34, various vibrating mechanisms 90 can be used toensure that the multi-component insulating material 14 is tightly packedand substantially evenly distributed throughout the insulating cavity16. Rotating mechanisms and air-pump mechanisms for generating an atleast partial vacuum can also be implemented to tightly pack themulti-component insulating material 14 within the insulating cavity. Inthis manner, it is contemplated that the various hollow insulatingspheres 38 of the plurality of hollow insulating spheres 38 that aredisposed within the multi-component insulating material 14 arepositioned to be in direct physical contact with at least one otheradjacent hollow insulating sphere 38 of the plurality of hollowinsulating spheres 38. It is also contemplated that at least a portionof the hollow insulating spheres 38 are separated from adjacent hollowinsulating spheres 38 where the multi-component insulating material 14includes larger proportions of the insulating powder material 24 andsmaller proportions of the hollow insulating spheres 38.

According to the various embodiments, it is contemplated that thecomponents of the multi-component insulating material 14 can be disposedwithin the insulating cavity 16 in a pattern, one at a time, or othersequential method. By way of example, and not limitation, it iscontemplated that larger particles, such as the hollow insulatingspheres 38, can be disposed in the insulating cavity 16 first, andprogressively smaller particulate material can be disposed within theinsulating cavity 16 thereafter. In this manner, as each smallerparticle material is disposed with the insulating cavity 16, the spacesbetween the larger particulate material can be filled by the smallerparticulate material. According to various embodiments, it iscontemplated that any porous areas 40 that exist between the variousparticles of the multi-component insulating material 14 can be filled orotherwise occupied by an insulating gas carrier 26. Accordingly, the useof the multi-component insulating material 14 can be used to fill orsubstantially fill the entire insulating cavity 16. As discussed above,gas 46 disposed within the insulating cavity 16 can be expressed throughone or more vacuum ports 44 to create the vacuum insulated structure 80.As further discussed above, the one or more gas inlets can be used inconjunction with the one or more vacuum ports 44 such that gas 46, suchas air, that is expressed from the insulating cavity 16 can be replacedby an insulating gas carrier 26 to increase the insulating properties ofthe multi-component insulating material 14.

It is contemplated that the components and component proportionsincluded within the multi-component insulating material 14 can varydepending upon the ultimate design, shape, size, desired performance,and other factors may bear on the ultimate design of the multi-componentinsulating material 14, and the appliance 12 as a whole.

Referring now to FIGS. 1-15, having described various aspects of aninsulation structure for an appliance 12 and/or a vacuum insulationpanel for an appliance 12, a method 400 is disclosed for forming aninsulating structure 10. According to the method 400, an insulatingmember, such as a cabinet 18 or panel, can be formed, where theinsulating member includes an interior surface 72 that defines aninsulating cavity 16 (step 402). As discussed above, the insulatingmember can be in the form of a cabinet 18 having an inner liner 22 andan outer wrapper 20, or can be in the form of a panel member that can beformed into a vacuum insulation panel for installation within theinsulating cavity 16 of an appliance 12. In addition to forming theinsulating member, an insulating powder material 24 can be formed aspart of the method 400 (step 404). The insulating powder material 24 canbe made of various nano-sized and/or micro-sized particulate materialthat can include, but is not limited to, fumed silica, precipitatedsilica, aerogel powder, perlite, rice husk ash powder, diatomaceousearth, cenospheres, combinations thereof, and other similar insulatingpowders. As discussed above, the insulating powder material 24 can becompacted to form portions of higher density that can take the form of agranular insulation material.

Referring again to FIGS. 1-4 and 15, according to the method 400, afterthe insulating member and the insulating powder material 24 are formed,the insulating powder material 24 can be disposed within the insulatingcavity 16 of the insulating member (step 406). In order to disperse theinsulating powder material 24 throughout the insulating cavity 16, aninsulating gas carrier 26 can be disposed into the insulating cavity 16(step 408). In this manner, when in an active state 32 moving throughthe insulating cavity 16, the insulating gas carrier 26 carries at leasta portion of the insulating powder material 24. This insulating powdermaterial 24 can thereby be suspended within the insulating gas carrier26 in the active state 32, which is referred to herein as the aeoliansuspension 34. As the insulating gas carrier 26 and the insulatingpowder material 24 move through the insulating cavity 16, the insulatingpowder material 24 can be deposited into the insulating cavity 16 byslowing the movement of the insulating gas carrier 26 to define adeposition state 36 (step 410). When the insulating gas carrier 26defines the deposition state 36, the insulating powder material 24precipitates from the insulating gas carrier 26 and settles within theinsulating cavity 16. In this manner, the insulating powder material 24is deposited substantially throughout the insulating cavity 16. Asdiscussed above, the step of depositing the insulating powder material24 can be performed by causing eddies 60, aerodynamic turbulence, and/orother formations that can cause a change in the speed and/or directionof movement of the aeolian suspension 34. These changes in movement canresult in the precipitation of the insulating powder materials 24 thatare then deposited within the insulating cavity 16.

Referring again to FIGS. 1-4 and 15, in order to retain the insulatinggas carrier 26 within the insulating cavity 16, the insulating member issealed in an airtight fashion (step 412). According to variousembodiments, at least a portion of the insulating gas carrier 26 and/orgasses 46 typically present within the insulating cavity 16, such asair, can be expressed from the insulating cavity 16, wherein theinsulating member defines a vacuum insulated structure 80 (step 414).

Referring again to FIGS. 2-4, it is contemplated that the insulating gascarrier 26 and the insulating powder material 24 can be disposed withinthe insulating cavity 16 as the aeolian suspension 34. To form theaeolian suspension 34, it is contemplated that the insulating gascarrier 26 can be fed through a container having an amount of theinsulating powder material 24. As the insulating gas carrier 26 movesthrough the insulating powder material 24, the insulating powdermaterial 24 becomes suspended within the insulating gas carrier 26moving in the active state 32. The insulating gas carrier 26 in theactive state 32, within which the insulating powder material 24 issuspended, is then delivered to the insulating cavity 16 of theinsulating structure 10 so that the insulating powder material 24 can bedeposited therein. It is also contemplated that the aeolian suspension34 can be formed within the insulating cavity 16 of the insulatingstructure 10. In such an embodiment, the insulating powder material 24can be injected, dropped, delivered, or otherwise disposed within theinsulating cavity 16 and the insulating gas carrier 26 can be blown orotherwise injected along separate paths that at least partiallyintersect within the insulating cavity 16. In this manner, theinsulating gas carrier 26 moves through portions of the insulatingpowder material 24 and forms the aeolian suspension 34 that, in turn,moves through the insulating cavity 16.

According to the various embodiments, it is contemplated that theinsulating gas carrier 26 can include, but is not limited to, argon,neon, carbon dioxide, xenon, krypton, combinations thereof, and othersimilar insulating gasses.

Referring again to FIGS. 2-4, in order to dispose the insulating gascarrier 26 and the insulating powder material 24 into the insulatingcavity 16, either individually, or combined as the aeolian suspension34, the insulating structure 10 can include at least one inlet port 42through which the insulating powder material 24 and the insulating gascarrier 26 can be injected into the insulating cavity 16. In order tofoster the movement of the insulating gas carrier 26 through theinsulating cavity 16, the insulating member can include one or morevacuum ports 44 from which gas 46 and portions of the insulating gascarrier 26 can be expressed from the insulating cavity 16. Theexpression of the gas 46 and insulating gas carrier 26 from the interiorcavity can further the movement of the insulating gas carrier 26 in theactive state 32 to allow the aeolian suspension 34 to be deliveredthroughout the insulating cavity 16 for even deposition of theinsulating powder material 24 throughout the insulating cavity 16. Inorder to further the deposition of the insulating powder material 24,the one or more vacuum ports 44 can be configured to permit expressionof the insulating gas carrier 26 and the gas 46 through the vacuum port44. Each vacuum port 44 is further configured to substantially retainthe insulating powder material 24 within the insulating cavity 16.Accordingly, each vacuum port 44 is sized to permit the movement of gas46 and the insulating gas carrier 26 therethrough, but includes a filtermechanism and/or a sized opening or openings that substantially preventthe movement of the insulating powder material 24 to move therethrough.Accordingly, the insulating powder material 24 can be retained withinthe insulating cavity 16 to eventually fill, or substantially fill, theinsulating cavity 16.

According to the various embodiments, it is contemplated that the method400 can be used in conjunction with larger particles that are disposedwithin the insulating cavity 16 either before the aeolian suspension 34is introduced or during injection of the aeolian suspension 34 into theinsulating cavity 16. These larger particles can include a granular formof the insulating powder material 24, hollow insulating spheres 38, andother similar larger particle insulating materials. When the aeoliansuspension 34 is injected through these larger materials, it iscontemplated that the use of the vacuum port 44 to draw gas 46 and theinsulating gas carrier 26 out from the insulating cavity 16 can help tomove the aeolian suspension 34 in the pores and spaces defined betweenthe larger particle material of the multi-component insulating material14. In this manner, the combination of the larger particle materials andthe aeolian suspension 34 can serve to uniformly distribute the variouscomponents of the multi-component insulating material 14 through theinsulating cavity 16.

Referring now to FIGS. 2-4 and 16, a method 500 is disclosed for formingan insulation member within an insulating structure 10. According to themethod 500, an insulating powder material 24 is formed (step 502) andthe insulating powder material 24 is suspended within an insulating gascarrier 26 to form an aeolian suspension 34 (step 504). In such anembodiment, the insulating gas carrier 26 is moved through theinsulating powder material 24 such that the insulating powder material24 can become suspended within the insulating gas carrier 26. Theaeolian suspension 34 is then deposited within an insulating cavity 16defined within an insulating structure 10 (step 506). At least a portionof the gas 46 and at least a portion of the insulating gas carrier 26can then be expressed from the insulating cavity 16 to promote airflowand to circulate the aeolian suspension 34 through the entirety of theinsulating cavity 16 (step 508). The movement of the aeolian suspension34 is slowed such that the insulating powder material 24 can precipitatefrom the aeolian suspension 34 (step 510). In this manner, theinsulating powder material 24 is deposited throughout the insulatingcavity 16. When the insulating powder material 24 is deposited in theinsulating cavity 16, the insulating gas carrier 26, having its movementslowed, changed in direction, or in some cases, stopped, can occupyvarious porous spaces defined between the particles of the insulatingpowder material 24. Once the insulating powder material 24 and theinsulating gas carrier 26 are uniformly distributed through theinsulating cavity 16, the insulating powder material 24 and insulatinggas carrier 26 can be sealed within the insulating cavity 16 to define avacuum insulated structure 80 (step 512).

Referring now to FIGS. 5-14 and 17, a method 600 is disclosed forforming an insulating structure 10. The method 600 includes forming aninsulating member (step 602). As discussed above, the insulating membercan include an interior surface 72 that defines an interior insulatingcavity 16. According to the method 600, a plurality of hollow insulatingspheres 38 can be formed (step 604), where the hollow insulating spheres38 are formed by moving micro- and/or nano-sized particles of organicand/or inorganic material along with a blowing agent through a flame,where the flame causes the blowing agent to decompose and release ahigh-temperature gas 46 that causes the particles of organic and/orinorganic material to expand, thereby forming the hollow insulatingspheres 38. As discussed above, these hollow insulating spheres 38 caninclude nano-spheres, microspheres, and other sized hollow insulatingspheres 38 that have an outside diameter in the range of fromapproximately 50 nanometers to approximately 300 microns.

Referring again to FIGS. 5-14 and 17, in addition to forming the hollowinsulating glass spheres 38, a fill material 74 is also formed (step606). According to various embodiments, the fill material 74 can bedefined by a nano/micro-sized particulate material. The hollowinsulating spheres 38 and the nano/micro-sized particulate material canthen be disposed within the interior insulating cavity 16 (step 608). Itis contemplated that the hollow insulating spheres 38 and thenano/micro-sized particulate material can be disposed within theinterior insulating cavity 16 at the same time. Alternatively, it iscontemplated that the hollow insulating spheres 38, typically beinglarger, can be disposed within the insulating cavity 16 before thenano/micro-sized particulate material. In this manner, thenano/micro-sized particulate material can infiltrate the secondaryinsulating volume 70 defined between adjacent hollow insulating spheres38. As discussed above, the thickness of the secondary insulating volume70 in a closed pack situation within the insulating cavity 16 can be inthe range of from approximately 40 nanometers to approximately 200microns. Sub-nano level thicknesses within the secondary insulatingvolume 70 are also contemplated. Because the nano/micro-sizedparticulate material is smaller than the gaps that define the secondaryinsulating volume 70, the nano/micro-sized particulate material can bedispersed throughout the secondary insulating volume 70 defined withinan interior insulating cavity 16 and within the interstitial spacedefined between the plurality of hollow insulating spheres (step 610).In this manner, the nano/micro-sized particulate material and the hollowinsulating spheres at least partially define the uniformly distributedmulti-component insulating material 14.

Referring again to FIGS. 5-14, it is contemplated that thenano/micro-sized particulate material can be distributed into thesecondary insulating volume 70 through the use of a vibrating mechanism90. In this manner, the vibrating mechanism 90 can cause a vibration ofthe insulating structure 10 and, in turn, the various components of themulti-component insulating material 14 such that the nano/micro-sizedparticulate material can be shaken between the interstitial spacedefined between the hollow insulating spheres 38 such that thenano/micro-sized particulate material can occupy substantially all ofthe secondary insulating volume 70 between the hollow insulating spheres38. It is also contemplated that the dispersion of the nano/micro-sizedparticulate material can be performed by injecting the insulating gascarrier 26 into the interior insulating cavity 16. In this manner, theinsulating gas carrier 26 can cause the nano/micro-sized particulatematerial to become suspended therein to form the aeolian suspension 34.The aeolian suspension 34 of the insulating gas carrier 26 and thenano/micro-sized particulate material can circulate through theinsulating cavity 16 and cause the deposition of the nano/micro-sizedparticulate material throughout the secondary insulating volume 70. Asdiscussed above, the vacuum port 44 can be used in conjunction with theaeolian suspension 34 to cause the circulation of the aeolian suspension34 through the secondary insulating volume 70 within the insulatingcavity 16.

According to the various embodiments, it is contemplated that the hollowinsulating insulating spheres 38 and the nano/micro-sized particulatematerial can be combined within the insulating cavity 16 at the sametime, such that the hollow insulating spheres 38 and thenano/micro-sized particulate material are disposed through the one ormore inlet port 42 at the same time. It is also contemplated that theinsulating structure 10 can include multiple inlet ports 42, where eachinlet port 42 is dedicated for depositing either the hollow insulatingspheres 38 or the nano/micro-sized particulate material into theinterior cavity. It is also contemplated that the hollow insulatingspheres 38 and the nano/micro-sized particulate material can define apre-mixed insulating material that is combined before being depositedinto the interior insulating cavity 16. In such an embodiment, it iscontemplated that the pre-mixed insulating material can be directlydisposed within the insulating cavity 16. It is also contemplated thatthe pre-mixed insulating material can be disposed into the insulatingcavity 16 along with an insulating gas carrier 26, such that theinsulating gas carrier 26 provides for the substantially even anduniform movement of the components of the multi-component insulatingmaterial 14 throughout the insulating cavity 16.

According to various embodiments, it is contemplated the use of theinsulating gas carriers 26 can cause hollow insulating spheres 38, suchas nano-spheres or microspheres, to become suspended within theinsulating gas carrier 26. In this manner, the aeolian suspension 34 canbe used to distribute the hollow insulating spheres 38, thenano/micro-sized particulate material, and other components of themulti-component insulating material 14 throughout the insulating cavity16. It is contemplated that certain components of the multi-componentinsulating material 14 may be too large to be suspended within theinsulating gas carrier 26 moving in the active state 32. In such anembodiment, it is contemplated that such a material that may besubstantially free of suspension within the insulating gas carrier 26can be deposited separately, typically before, the aeolian suspension 34is introduced into the insulating cavity 16.

Referring again to FIGS. 5-13 and 18, a method 700 is disclosed forforming a multi-component insulating material 14 to be used in aninsulating structure 10, such as an appliance 12. According to themethod 700, a plurality of hollow insulating spheres 38 are formed,wherein a secondary insulating volume 70 is defined within aninterstitial space defined between the plurality of hollow insulatingspheres 38 (step 702). As discussed above, the hollow insulating spheres38 can include microspheres having a diameter of from approximately 15microns to approximately 300 microns and can also include nano-spheresthat have a diameter of from approximately 50 nanometers toapproximately 1000 nanometers. It is contemplated that hollow insulatingspheres 38 having larger and smaller diameters can be used within theinsulating cavity 16 and as part of the multi-component insulatingmaterial 14. According to the method 700, a fill material 74 is alsoformed (step 704). It is contemplated that the fill material 74 can bedefined by the nano/micro-sized particulate material,nano/micro-spheres, the insulating powder material 24, combinationsthereof, and other nano/micro-sized insulating particulate material. Thenano/micro-sized particulate material is then dispersed throughout thesecondary insulating volume 70 defined between the hollow insulatingspheres 38 (step 706). In this manner, the nano/micro-sized particulatematerial and hollow insulating spheres 38 at least partially define thesubstantially uniform dispersion of the various components of themulti-component insulating material 14 throughout a particular space. Itis contemplated that the multi-component insulating material 14 can beformed outside of the insulating cavity 16 and disposed therein afterformation of the multi-component insulating material 14. It is alsocontemplated that the multi-component insulating material 14 can beformed within the insulating cavity 16, such that various components aredisposed within the insulating cavity 16 one at a time or in smallercombinations to ultimately form the multi-component insulating material14.

Referring to FIGS. 10-13, according to an exemplary process for formingthe multi-component insulating material 14, the insulating cavity 16 ofthe insulating structure 10 is provided (as exemplified in FIG. 10). Itis contemplated that the insulating structure 10 can be a cabinet 18,door, panel, or other unit of an insulating structure 10 for anappliance 12. It is also contemplated that the insulating structure 10can be a panel member that ultimately forms a vacuum insulated panelthat is separately installed within the insulating structure 10.According to the exemplary process illustrated in FIGS. 10-13, FIG. 10exemplifies the deposition of the hollow insulating spheres 38 withinthe insulating structure 10. Typically, the hollow insulating spheres 38represent the component having the largest particle size of themulti-component insulating material 14. As exemplified in FIG. 12, thenano/micro-sized particulate material can be blown into the insulatingcavity 16 to occupy the secondary insulating volume 70 defined betweenthe hollow insulating spheres 38. It is contemplated that an insulatinggas carrier 26 can be used to blow the nano/micro-sized particulatematerial into the insulating cavity 16. It is also contemplated that airor some other gaseous material can be used as a carrier for deliveringthe nano/micro-sized particulate material into the secondary insulatingvolume 70. According to FIG. 13, an insulating gas carrier 26 can thenbe injected into the insulating structure 10. Typically, a vacuum port44 is used in conjunction with the inlet port 42, where the vacuum port44 expresses gas 46, and at least a portion of the insulating gascarrier 26 from the insulating cavity 16. In this manner, the gas 46expressed from the interior cavity can be replaced by the insulating gascarrier 26 to increase the insulating characteristics of the insulatingstructure 10. It is contemplated that each of the components of themulti-component insulating material 14 can define a homogenous, orsubstantially homogenous, material. In this manner, the nano/micro-sizedparticulate material can be substantially homogenous. Alternatively, thenano/micro-sized particulate material can include compressed portions ofgranulated insulating material spaced within the remainder of thenano/micro-sized particulate material. The result of the combination ofthe various components, as exemplified in FIG. 14, is a substantiallyeven or uniform distribution of the various components of themulti-component insulating material 14 throughout the insulating cavity16 of the insulating structure 10. In this manner, the insulatingmaterial 14 can provide thermal and/or acoustical insulating propertiesto the insulating cavity 16 of the appliance 10. Additionally, each ofthe components, having either gaseous characteristics or havingdifferent particle sizes, can, in combination, serve to occupy all, orsubstantially all, of the interior volume of the insulating cavity 16.

According to the various embodiments, it is contemplated that theinsulating structure 10, when in the form of a cabinet 18, can includean inner liner 22 and outer wrapper 20 that are made up of variousmaterials that can include, but are not limited to, high barrierplastic, metal, polymer, combinations thereof, and other substantiallyrigid materials that can form a hermetic seal. This seal can be formedby one of varying methods that can include, but are not limited to,crimping, folding, welding, adhering, adhesive bonding, fastening,combinations thereof, and other similar sealing techniques that can forma hermetic seal between like materials or dissimilar materials,depending upon the configuration of the insulating structure 10.

According to the various embodiments, while a refrigerating appliance 12is exemplified in FIG. 1, it is contemplated that the various aspects ofthe device can be utilized within various fixtures and/or appliances 12,wherein the term “appliance” can include cabinets, doors, and/orinsulating structures therefor. Such appliances 12 and/or fixtures caninclude, but are not limited to, freezers, refrigerators, coolers,ovens, dishwashers, laundry appliances, water heaters, householdinsulation systems, ductwork, piping insulation, acoustical insulation,and other insulating applications.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method of forming an insulating structure, themethod comprising steps of: forming an insulating member, wherein theinsulating member includes an interior surface that defines aninsulating cavity; forming an insulating fill material; disposing theinsulating fill material within the insulating cavity; dispersing theinsulating fill material throughout the insulating cavity by disposingan insulating gas carrier into the insulating cavity, wherein aninsulating gas in an active state carries at least a portion of theinsulating fill material within the insulating gas carrier in the activestate, wherein the active state is defined by the insulating gas carrierbeing moved within the insulating cavity; depositing the insulating fillmaterial into the insulating cavity by slowing movement of theinsulating gas carrier to define a deposition state, wherein when theinsulating gas carrier defines the deposition state, the insulating fillmaterial precipitates from the insulating gas carrier and settles withinthe insulating cavity, wherein the insulating fill material is depositedsubstantially throughout the insulating cavity, wherein the depositionstate of the insulating gas carrier is at least partially defined bycreating eddies within the insulating gas carrier, wherein the eddiesare generated using turbulence producing structures within theinsulating cavity; sealing the insulating member; and expressing atleast a portion of the insulating gas carrier from the insulating cavityto define a vacuum insulated structure.
 2. The method of claim 1,wherein the insulating member is a cabinet having an outer wrapper andan inner liner sealed together, and wherein the insulating cavity isdefined between the outer wrapper and the inner liner, and wherein thevacuum insulated structure is a thermally insulating structure, whereinthe turbulence producing structures are attached to the interior surfaceof the insulating member.
 3. The method of claim 2, wherein theinsulating member includes an inlet port through which the insulatingfill material and the insulating gas carrier are injected into theinsulating cavity, and wherein the cabinet includes a vacuum port fromwhich gas and portions of the insulating gas are expressed from theinsulating cavity.
 4. The method of claim 3, wherein during thedispersing and deposition steps, the gas and at least a portion of theinsulating gas carrier are contemporaneously expressed from the vacuumport, wherein the vacuum port is configured to permit expression of theinsulating gas carrier, and wherein the vacuum port is configured tosubstantially retain the insulating fill material within the insulatingcavity, wherein contemporaneous performance of the dispersion,deposition and expression steps forms the vacuum insulated structure. 5.The method of claim 1, wherein the insulating member is a panel memberand the vacuum insulated structure defines a vacuum insulated panel. 6.The method of claim 1, wherein the insulating gas carrier is at leastone of argon, neon, carbon dioxide, xenon and krypton.
 7. The method ofclaim 1, wherein the insulating fill material includes insulating glassspheres.
 8. The method of claim 1, wherein the step of dispersing theinsulating fill material throughout the insulating cavity is performedby blowing the insulating gas carrier through the insulating fillmaterial.
 9. The method of claim 1, wherein the insulating gas carrierand the insulating fill material are combined within the insulatingcavity, wherein the insulating fill material becomes suspended withinthe insulating gas carrier in the active state within the insulatingcavity.